Best Rebuild Order

[MentalScientist]

Posted this on the XT600 section but probably best placed here:

Happy New Year to everyone reading :)

I'm finally in the process of rebuilding my XT600 after stripping it down about a year. I've had the frame powder coated and I'm cleaning everything up ready to go back together.

I'd really like peoples advice and experience about the best way of rebuilding the bike. I've restored an old DT250MX before and I remember getting the the bike rolling first, then lifting the engine into place. That was a lot lighter engine so in my mind, for this bike, I was thinking of fitting the engine to the frame first and then the rear swingarm, followed by the front forks and wheel and finally the rear wheel.

I should also add that I'm doing this in my kitchen so very limited workshop facilities!

I fully expect to be made to look like an idiot with much easier methods so fire away!

[Patrick]

Something important to remember is that there is no frame running under the engine, so how you do it will be determined by what kind of lifts/jacks/cranes/milk crates you have at your disposal as there is no easy way to lift the frame onto the engine or to support the engine on a stand and lift it into the frame.
Others may say otherwise, but in my opinion, the swing arm is most easily installed at the same time as the engine. For this reason, the first stage of my ground up rebuild is the engine and rear swing arm. This is made easier for me though as I have a shop crane and can suspend the whole setup from above. I am able to install the engine and swing arm together and then worry about wheels later.
Regardless of which method you go with if it is your first time you're likely going to struggle. I've had the engine in and out a few times now and nothing really goes together easily. The engine weighs just shy of a metric shit ton and the mounts can be fiddly. Best have a second set of hands if you can.

All that said, there are blokes on this forum much more experienced than I and hopefully, they can give you some better advice. Don't forget to throw up some progress pics so we can check out how it all goes.

[Mezo]

I did this on my own (no flashy ramp or crane) but i laid the engine on its side (cardboard) & slid the or "offered" the frame up.

EDIT: I had removed the engine cases (covers) to stop them getting scratched.

Mezo.